THz Array SAR Measurement for Plastic Profile Layers
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Solution Overview
Problem
Existing methods struggle to accurately measure complex plastic profiles with multiple layers, cavities, and non-parallel surfaces, as they require direct line-of-sight and cannot handle angular or curved surfaces effectively, limiting precision and applicability.
Innovation Solution
Combining active phased array THz transceivers with synthetic aperture radar (SAR) technology to create a high-definition virtual model of the plastic profile by overlapping radiation cones and using SAR evaluation algorithms to determine layer thicknesses and surface positions, allowing for precise measurement of complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional THz measurement methods are used, then simple plastic profiles can be measured easily, but complex plastic profiles with multiple layers, cavities, and non-parallel surfaces cannot be measured accurately
Solution Approach 1:
The patent transitions from single-point THz measurement to a distributed array of THz transceivers arranged in multiple dimensions (x, y, z coordinates). This spatial arrangement enables measurement of complex three-dimensional plastic profiles with multiple layers and cavities by capturing reflections from various angles and positions simultaneously, resolving the limitation of traditional single-point methods that can only measure simple profiles.
Solution Approach 2:
The measurement system is divided into multiple independent THz transceivers arranged in an array, with each transceiver independently measuring reflections from specific regions. This segmentation allows the complex measurement task of characterizing multi-layer profiles with cavities to be divided into multiple simpler sub-measurements, each handled by individual transceivers, thereby achieving comprehensive coverage of complex geometries.
2Measurement precision
If a single THz transceiver is used, then the device complexity is low, but the ability to determine multiple layer thicknesses and surface positions is limited
Solution Approach 1:
Each THz transceiver in the array is designed to perform multiple functions: it can measure reflections from different layers, determine surface positions, and characterize complex geometries. The transceivers operate universally across different measurement tasks by capturing THz radiation reflections that contain information about multiple layers and surfaces, eliminating the need for separate specialized measurement devices for each function.
Solution Approach 2:
The patent combines multiple THz transceivers into a unified measurement array that operates simultaneously to capture comprehensive reflection data. By merging the capabilities of individual transceivers into a coordinated array system, the solution achieves superior measurement precision for multiple layer thicknesses and surface positions while managing device complexity through integrated control and processing of the array outputs.
3Measurement precision
If THz radiation is emitted at perpendicular angles only, then the measurement process is simple, but angular and curved surfaces cannot be measured accurately
Solution Approach 1:
The patent extends measurement from single perpendicular angle to multiple angular dimensions by arranging THz transceivers in three-dimensional space. This spatial distribution enables the system to capture reflections from angular and curved surfaces at various incident angles, providing comprehensive characterization of complex surface geometries that cannot be measured by single-angle perpendicular emission.
Solution Approach 2:
The measurement system dynamically adjusts the effective measurement geometry by activating different transceiver pairs based on the target region and surface orientation. This dynamic configuration allows the system to adapt to various surface geometries (angular, curved, flat) by selecting appropriate transceiver combinations and measurement angles, achieving precise measurement without requiring physical reconfiguration of the entire apparatus.
4Area of stationary object
If multiple THz transceivers are arranged in a large array, then the coverage area is large, but the time to acquire and process measurement data increases
Solution Approach 1:
The THz transceiver array operates continuously and simultaneously to capture reflections from all target regions, eliminating sequential measurement steps. Each transceiver continuously monitors its region for THz radiation reflections, and the system continuously processes data from all transceivers in parallel, maintaining uninterrupted measurement action that reduces total acquisition time while covering large areas.
Solution Approach 2:
The patent employs a distributed array where only the necessary subset of transceivers actively measures specific regions at any given time, while other transceivers remain in standby or perform auxiliary functions. This partial action approach allows the system to cover large areas through coordinated operation of multiple transceivers without requiring all transceivers to be actively processing data simultaneously, thereby reducing overall processing time while maintaining comprehensive coverage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise determination of layer thicknesses and surface features in complex plastic profiles, including those with cavities and sealing lips, by generating a high-definition virtual model, facilitating real-time adjustment of extrusion processes.
Implementation Method 1
a THz transmission beam is irradiated perpendicular onto the respective measured object and is partially reflected on boundary surfaces so that the boundary surfaces can be determined as measuring peaks from the reflection radiation
Data Source
AI summary
The present disclosure relates to a measuring system for measuring a measured object, in particular a plastic profile, said measuring system comprising:an antenna arrangement of THz transceivers each at times actively emitting a THz transmission beam and passively receiving reflected THz radiation,where said antenna arrangement outputs measuring signals of the measurements of the THz transceivers,an adjustment means for adjusting the antenna arrangement into several measuring positions along an adjustment direction,a control and evaluation device for receiving and evaluating the measuring signals which is configured such that the measuring signals are evaluated by means of a synthetic aperture radar evaluation process and a virtual model of the boundary surfaces of the measured object is created, andsubsequently the control and evaluation device determines layer thicknesses between the boundary surfaces from the virtual model.